Multi-layer female component for refastenable fastening device and method of making the same

Abstract

The present invention provides a female component for engaging a complementary hook component in a refastenable fastening device. The female component of the present invention is capable of engaging a hook component that has flexible, resilient individual hook elements. The female component comprises at least two, and preferably three zones or layers. Each zone has certain of the desired individual characteristics for entangling and holding the hooks of the mating hook component. These include a first zone for admitting and engaging at least some of the hooks of the complementary hook component (the "entanglement" zone), a second zone for providing space for the hooks to occupy after they have been admitted by the entanglement zone (referred to as the "spacing" zone), and a backing adjacent to the spacing zone for providing a foundation for the entanglement and spacing zones. The present invention also provides a fastening device having a hook fastening component and a female component that comprises the multi-layer female component of the present invention. The present invention also relates to disposable articles and more particularly to a disposable diaper having such an improved fastening device.

What is claimed is: 
     
       1. A multi-zone female component for a refastenable fastening device that is capable of engaging a complementary hook fastening component which has a base with individual hooks extending outward from said base, and said hooks comprise a stem supported at one end on said base and a blunt head on the opposite end of said stem, said multi-zone female component comprising: an entanglement zone for admitting and mechanically entangling at least some of the hooks of the complementary hook component, said entanglement zone comprising a first material having a thickness, said first material comprised of at least one structural element, said first material being capable of providing a multiplicity of openings for said hooks so that a plurality of said hooks of said hook component may readily penetrate said thickness of said first material without forcibly piercing said first material;   a spacing zone comprising a second material adjacent said entanglement zone for providing space for at least portions of said hooks to occupy after said hooks have penetrated said entanglement zone;   a backing comprising a third material adjacent said spacing zone for providing a foundation for said entanglement zone and said spacing zone, wherein said entanglement zone and said spacing zone are held in place with respect to said backing with said spacing zone in between said entanglement zone and said backing; and a joining means for joining said first material with said third material.   
     
     
       2. The multi-zone female component of claim 1 wherein said entanglement zone comprises a first material selected from the group consisting of: a nonwoven web comprised of plurality of fibers, said nonwoven web being capable of providing interstices between said fibers; a woven material comprised of a plurality of yarns that define interstices therebetween; a screen comprised of a plurality of structural elements that define interstices therebetween; a perforated film having perforations that define interstices in said perforated film; and a foam having interstices therein. 
     
     
       3. The multi-zone female component of claim 1 wherein said spacing zone comprises a second material selected from the group consisting of: (a) at least one nonwoven web; (b) at least one layer of woven material; (c) at least one thickness of a screen; and, (d) a plurality of loose particles. 
     
     
       4. The multi-zone female component of claim 3 wherein the complementary hook fastening component has hooks which have an overall height, and the heads of said hooks have a length, a width, a height, the length and width defining the projected plan view dimensions of the heads of said hooks, and said second material comprises at least one thickness of a screen having interstices with dimensions that are larger than the projected plan view dimensions of the heads of said hooks. 
     
     
       5. The multi-zone female component of claim 3 wherein said backing comprises a material selected from the group consisting of: a film, a nonwoven web of material, and a woven fabric. 
     
     
       6. The multi-zone female component of claim 5 wherein the caliper of said entanglement zone is less than or equal to the overall height of the hooks. 
     
     
       7. The multi-zone female component of claim 6 wherein the caliper of said spacing zone is greater than or equal to the height of the heads of the hooks. 
     
     
       8. A multi-zone female component for a refastenable fastening device that is capable of engaging a complementary hook fastening component which has a base with individual hooks extending outward from said base said hooks comprising a stem supported at one end on said base and a blunt head on the opposite end of said stem, said multi-zone female component comprising: an entanglement zone for admitting and mechanically entangling at least some of said hooks of said complementary hook component, said entanglement zone comprising a first material having a thickness, said first material comprised of at least one structural element, said first material being capable of providing a multiplicity of openings for said hooks so that a plurality of said hooks of said hook component may readily penetrate said thickness of said first material without forcibly piercing said first material;   a spacing zone adjacent said entanglement zone for providing space for at least portions of said hooks to occupy after said hooks have penetrated said entanglement zone; and   a backing adjacent said spacing zone for providing a foundation for said entanglement zone and said spacing zone, wherein said entanglement zone and said spacing zone are held in place with respect to said backing with said spacing zone in between said entanglement zone and said backing;   said entanglement zone comprising a first material selected from the group consisting of: a nonwoven web comprised of a plurality of fibers, said nonwoven web being capable of providing interstices between said fibers; a woven material comprised of a plurality of yarns that define interstices therebetween; a screen comprised of a plurality of structural elements that define interstices therebetween; a perforated film having perforations that define interstices in said perforated film; and a film having interstices therein;   said hooks of said complementary hook fastening component having an overall height, and said heads of said hooks having a length, a width, a height, said length and width defining projected plan view dimensions of said heads of said hooks, and said interstices are larger than said projected plan view dimensions of said heads of said hooks.   
     
     
       9. The multi-zone female component of claim 8 wherein said interstices have dimensions that are greater than about 0.5 mm. by about 0.2 mm. 
     
     
       10. A multi-zone female component for a refastenable fastening device that is capable of engaging a complementary hook fastening component which has a base with individual hooks extending outward from said base, said hooks comprising a stem supported at one end on said base and a blunt head on the opposite end of said stem, said multi-zone female component comprising: an entanglement zone for admitting and mechanically entangling at least some of said hooks of said complementary hook component, said entanglement zone comprising a first material having a thickness, said first material comprised of at least one structural element, said first material being capable of providing a multiplicity of openings for said hooks so that a plurality of said hook component may readily penetrate said thickness of said first material without forcibly piercing said first material;   a spacing zone adjacent said entanglement zone for providing space for at least portions of said hooks to occupy after said hooks have penetrated said entanglement zone, wherein said spacing zone comprises a second material selected from the group consisting of: (a) at least one nonwoven web; (b) at least one layer of woven material; (c) at least one thickness of a screen; and (d) a plurality of loose particles; and   a backing adjacent said spacing zone for providing a foundation for said entanglement zone and said spacing zone, wherein said entanglement zone and said spacing zone are held in place with respect to said backing with said spacing zone in between said entanglement zone and said backing;   said complementary hook fastening component having hooks which have an overall height, and the heads of said hooks having a length, a width, a height, the length and width defining projected plan view dimensions of said heads of said hooks, and said second material comprising at least one layer of woven material or at least one screen having interstices with dimensions that are larger than said projected plan view dimensions of said heads of said hooks.   
     
     
       11. A multi-zone female component for a refastenable fastening device that is capable of engaging a complementary hook fastening component which has a base with individual hooks extending outward from said base, said hooks comprising a stem supported at one end on said base and a blunt head on the opposite end of said stem, said multi-zone female component comprising: an entanglement zone for admitting and mechanically entanglement at least some of said hooks of said complementary hook component, said entanglement zone comprising a first material having a thickness, said first material comprised of at least one structural element, said first material being capable of providing a multiplicity of openings for said hooks so that a plurality of said hook component may readily penetrate said thickness of said first material without forcibly piercing said first material;   a spacing zone adjacent said entanglement zone for providing space for at least portions of said hooks to occupy after said hooks have penetrated said entanglement zone, wherein said spacing zone comprises loose particles having a largest dimension of less than or equal to said overall height of said hooks of said mating hook component; and   a backing adjacent said spacing zone for providing a foundation for said entanglement zone and said spacing zone, wherein said entanglement zone and said spacing zone are held in place with respect to said backing with said spacing zone in between said entanglement zone and said backing.   
     
     
       12. A multi-zone component that is affixed to a substrate to form a female component for a refastenable fastening device, said female component being capable of engaging a complementary hook fastening component which has a base with individual hooks having blunt heads extending outward from said base, said multi-zone component comprising: an entanglement zone comprising a first material for admitting and mechanically entangling at least some of said hooks of said complementary hook component, said entanglement zone comprising a first material having a thickness, said first material comprised of at least one structural element, said first material being capable of providing a multiplicity of openings for said hooks so that a plurality of said hooks of said hook component may readily penetrate said thickness of said first material without forcibly piercing said first material;   a spacing zone comprising a second material for providing space for at least portions of said hooks to occupy after said hooks have penetrated said entanglement zone, wherein   said entanglement zone and said spacing zone are held in place with respect to said substrate with said spacing zone in between said entanglement zone and said substrate; and   a first joining means for joining said first material with said substrate.   
     
     
       13. The multi-zone component of claim 12 further comprising a second joining means joining said first material with said second material and a third joining means joining said second material with said substrate. 
     
     
       14. A fastening device comprising a hook fastening material comprising a base and a plurality of engaging elements extending from said base, and the female component of claims 1, 8 or 3. 
     
     
       15. A disposable absorbent article comprising: a body portion having an inside surface, an outside surface, longitudinal edges, end edges, a first waist region, and a second waist region, said body portion comprising a liquid pervious topsheet, a liquid impervious backsheet joined to said topsheet, and an absorbent core between said topsheet and said backsheet; and   a mechanical fastening system positioned on said body portion comprising a tab attached to the first waist region of said body portion adjacent each longitudinal edge, each of said tabs comprising a hook fastening component disposed on at least a portion of said tab, and   the female component of claims 1, 8 or 3, disposed on said outside surface of said body portion in said second waist region, said female component being mechanically engageable with said hook fastening component.     
     
     
       16. The disposable absorbent article of claim 15 wherein the entanglement zone is comprised of a plurality of structural elements which are generally parallel to said longitudinal edges of said disposable absorbent article. 
     
     
       17. The multi-zone female component of claims 1 or 3 further comprising a second joining means joining said first material with said second material and a third joining means joining said second material with said third material.